Well Screen Design For Enhanced Horizontal Flow Filtration Control

ABSTRACT

Embodiments and methods relate to a subsurface, well screen apparatus having a rib wire connected to a wire wrap, where the wire wrap enhances a volume of fluid and/or gas flow for reducing pressure drop via the well screen and/or has an inverted orientation as compared with prior designs. Embodiments and methods may also utilize a wire wrap that has a generally triangular shaped and/or triangular shaped cross-sectional profile. Embodiments and methods may also reverse the orientation of the rib wire and wire wrap. The effect of the embodiments and methods is enhanced horizontal flow filtration control.

BACKGROUND Technical Field

The embodiments relate to a subsurface screening device for water, oil, and/or gas.

Wire wrap screens have been in use for approx. 100 yrs., most all employ a “keystone”, or trapezoid shaped wire. This wire has the flat side facing out to control the inflow of solids. Typically it is between 0.120″-0.040″ on the outer face, most likely 0.090″ wide×0.140 or 0.125″ high, welded to a round or similar shaped under rib. The spacing between the individual wires controls the filtration. In all designs used in a “shroud” configuration only the opposing open area allows for direct communication of produced liquids/gas etc. Vertical flow is a limiting factor—horizontal flow is preferred since it has reduced pressure drop. To get a comparison, a wire wrap screen with a 0.090″ wire, spaced at 0.012″ (in order to control 20-40 mesh frac sand) has about a 13% direct horizontal flow area exposed. The typical perforated shroud has about ⅛″ to 5/16″ (hole) opening—which only allows inlet area—not a filtration component.

Current premium screen designs employ a protective “shroud” component to either protect or enclose sized media (gravel/beads, diffusion bonded sintered laminate SS, or non-sintered SS woven wire etc.) in order to serve as the filtration “layer” that provides exclusion of produced solids. This is generally done with a perforated rolled & welded perforated (or punched) sheet metal exterior tube, or a conventional resistance welded wire-wrap or slotted liner design. The accepted normal design for the shroud (rolled sheet metal) allows a 14-16 ga. thickness that allows for approx. 23-30% open area. This is a limiting factor as it is the first line of communication of flow to the component media(s) that are contained within the apparatus. For comparative purposes refer to www. Deltascreens.com, Weatherford, Superior energy, BOT, etc. all have a version of this design.

SUMMARY

Embodiments and methods relate to a subsurface, well screen apparatus having a rib wire connected to a wire wrap, where the wire wrap enhances a volume of fluid and/or gas flow for reducing pressure drop via the well screen and/or has an inverted orientation as compared with prior designs. Embodiments and methods may also utilize a wire wrap that has a generally triangular shaped and/or triangular shaped cross-sectional profile. Embodiments and methods may also reverse the orientation of the rib wire and wire wrap. The effect of the embodiments and methods is enhanced horizontal flow filtration control.

As used herein the terms “well screen” can mean “shroud” and particularly in the claims.

BRIEF DESCRIPTION OF THE DRAWINGS

The exemplary embodiments may be better understood, and numerous objects, features, and advantages made apparent to those skilled in the art by referencing the accompanying drawings. These drawings are used to illustrate only exemplary embodiments, and are not to be considered limiting of its scope, for the disclosure may admit to other equally effective exemplary embodiments. The figures are not necessarily to scale and certain features and certain views of the figures may be shown exaggerated in scale or in schematic in the interest of clarity and conciseness.

FIG. 1 depicts a sectional view of an exemplary embodiment of a well screen in a horizontal well or bore according to the improvements disclosed herein.

FIG. 2 depicts a sectional view of an exemplary embodiment of a well screen in a horizontal well or bore according to the improvements disclosed herein.

FIG. 3 depicts a sectional view of an exemplary embodiment of a well screen in a horizontal well or bore according to the improvements disclosed herein

FIG. 4 depicts of a cross-sectional view of an embodiment of an outside wire according to the improvements disclosed herein.

DESCRIPTION OF EMBODIMENT(S)

The description that follows includes exemplary apparatus, methods, techniques, and instruction sequences that embody techniques of the inventive subject matter. However, it is understood that the described embodiments may be practiced without these specific details.

Referring to FIGS. 1-4, this new design employs resistance welded wire wrap technology in a unique configuration as applied to subsurface and/or sub-water surface production premium well screen designs, and offers a greater inflow capacity while offering another layer of filtration capability. The well screen 10 is adapted to be mounted subsurface in, for example, a formation to screen out aggregate and allow flow of fluids and/or gases, principally oil, water, and/or gas. The well screen 10 may have a rib wire connected to a wire wrap, where the wire wrap comprises a means for enhancing a volume of fluid and/or gas flow for reducing pressure drop via the well screen. The wire wrap has an inward facing side 32 and an outward facing side 34. The length of the outward facing side 34 may be shorter than the length of the inward facing side 32. The rib wire 20 may be connected to the outward facing side 34 or the inward facing side 32.

FIGS. 1-3 show a well screen 10 embodiment with the rib wire/inside wire 20 welded or attached to the outside wire wrap 30. The well screen 10 enhances the flow and reduces or lowers pressure drop. The flow enhancement may be attributable to increasing flow without increasing flow velocity (or even reducing flow velocity). By reducing flow velocity one may reduce erosion of the well screen 10. FIGS. 1-2 indicate the flow direction 70 of water, oil, gas, or other fluid. The outside wire 30 has the “flat” side or long/longer side 32 of the triangular or generally triangular shape 36 of the outside wire 30 facing in an inner/inward facing direction 12 (this is the inverted design and triangular may generally be trapezoidal assuming the apex is not merely an infinitesimal point but a side). The apex/pointed (thin) part or short/shorter side 34 of the outside wire 30 is facing in the outwardly facing direction 14 (and results in a first flow positon of fluid and/or gas proximate the apex or shorter side 34, as compared or relative to a second flow position proximate the longer or flat side 32). This creates a funnel effect (see arrows of flow direction 70 in FIG. 2 at the flow production interface between aggregate 40 and the well screen 10) to enhance flow for use downhole in, for example, a horizontal well for well production.

By taking the trapezoid shaped wire and inverting it offers a greater amount of “captured material” to provide inflow to the controlled filtration opening. As with all wire wrapped screens this can be controlled to a standard of +0.001″/−0.002″. This new embodiment of a well screen 10 provides a funnel effect. This is enhanced further by shaping the outside wire 30 to a more triangular shape 36. This takes full advantage of the “funnel” effect to deliver more horizontal flow to the controlled filtration opening offering better drainage of the reservoir. This design of the outside wire 30 is also completely welded at every juncture & is preferred against other current designs for resistance to impact damage. Impact damage can be caused by slips, tongs, hammers, downhole unknowns, etc. In this embodiment the larger flat surface 32 is welded to a rib 20 on the interior and that is where the controlling filtration occurs—not on the outside as is current design. Therefore any type of outside impacts will not cause a “hot spot” where erosion is likely to occur with failure. This new design of a well screen 10 is best employed in stand-alone (a.k.a. open hole/barefoot) completion applications where either formation sand or frac sand (media) 40 is allowed to interface with the well screen 10. Since this new shroud design can be filtration adjusted to actually capture more flow while providing an extra layer of protection for the components it protects is an extra benefit. This design allows the wire wrapped (inverted) well screen 10 to either be slipped over (as in prepacked applications) or slipped over or direct wrapped over filter media. This well screen 10 can either be directly welded to perforated pipe as well as employed as protection/filtration over another layer of filtration between it and the perforated pipe.

In exemplary embodiments perforated pipe 50 may be mounted in the interior to the inside rib wire 20 and outside wire wrap 30. Another filter device (secondary/primary additional filter component) 60 may be disposed in the small annular (open) space between the perforated pipe 50 and the combination of the inside rib wire 20 and outside wire wrap 30 in exemplary embodiments. The filter device (secondary/primary additional filter component) 60 may, for example, but not limited to, be a cloth, wire cloth sintered laminate, sized gravel, etc. Or, the combination of the inside rib wire 20 and outside wire wrap 30 can also be direct wrapped onto the perforated pipe 50 as well (without any other intermediate filter media).

Referring to FIG. 4, the flat side 32 in one embodiment may be about 0.060 inch(es),and the apex/point side 34 is a bit less than 0.020 inch(es).

The exemplary embodiments have increased contact area between the inside horizontal rib wire 20 and outside wrap wire 30 for an improved weld interface over prior art. The/such weld surfaces of the exemplary embodiments have stronger resistance to pull forces. Additionally, the opening size 38, defined between each consecutive wrap of wire 30 and measured between consecutive flat sides 32 of wrap wire 30, is less likely to be damaged, therefore eliminating or lessening the likelihood of a “hot spot” forming. The opening size 38 may be measured photometrically. The exemplary embodiments also exhibit a better self-cleaning characteristic of the fines in the annular space between the perforated pipe 50 and the inside horizontal rib wire 20.

In another exemplary embodiment, the position and/or the orientation of the rib wire and wire wrap may be reversed where the horizontal rib wire 20 is located outside of the wire wrap 30; the wire wrap 30 would be inside of the horizontal rib wire 20.

In one exemplary embodiment, the premium well screen in a protective shroud design is implemented for enhanced horizontal flow filtration control. The well screen design may be implemented as a shroud and/or a screen.

While the embodiments are described with reference to various implementations and exploitations, it will be understood that these embodiments are illustrative and that the scope of the inventive subject matter is not limited to them. Many variations, modifications, additions and improvements are possible. The methods employed may include method(s) for making the apparatus embodiments described.

Plural instances may be provided for components, operations or structures described herein as a single instance. In general, structures and functionality presented as separate components in the exemplary configurations may be implemented as a combined structure or component. Similarly, structures and functionality presented as a single component may be implemented as separate components. These and other variations, modifications, additions, and improvements may fall within the scope of the inventive subject matter. 

1. A method of providing a well screen in a subsurface environment for screening aggregate from and allowing flow of a volume of fluid and/or gas, comprising the steps of: mounting the well screen in the subsurface environment; and enhancing the flow for reducing pressure drop via the well screen.
 2. The method of claim 1, wherein the step of enhancing the flow for reducing pressure drop via the well screen comprises funneling the fluid and/or gas in a flow direction.
 3. The method of claim 1, wherein the step of enhancing the flow for reducing the pressure drop via the well screen comprises filtering the aggregate from the fluid and/or gas.
 4. The method of claim 1, wherein the well screen comprises a rib wire connected to a wire wrap, wherein the wire wrap has an inward facing side and an outward facing side.
 5. The method of claim 4, wherein the rib wire connects to the wire wrap on the inward facing side of the wire wrap.
 6. The method of claim 4, wherein the rib wire connects to the wire wrap outer facing side of the wire wrap.
 7. The method of claim 4 wherein the wire wrap has a trapezoidal cross-sectional profile.
 8. The method of claim 4 wherein the wire wrap has a cross-sectional profile having a triangular shape.
 9. The method of claim 4 wherein the inward facing side of the wire wrap is longer and the outward facing side of the wire wrap is relatively shorter.
 10. A well screen apparatus for use in a subsurface environment, comprising: a rib wire connected to a wire wrap; and wherein the wire wrap comprises a means for enhancing a volume of fluid and/or gas flow for reducing pressure drop via the well screen.
 11. The well screen apparatus according to claim 10, wherein said means for enhancing the volume of fluid and/or gas flow for reducing pressure drop via the well screen comprises a means for funneling the volume of fluid and/or gas flow in a flow direction.
 12. The well screen apparatus according to claim 10, wherein the wire wrap has an inward facing side and an outward facing side, wherein the rib wire is connected to the wire wrap at the inward facing side of the wire wrap.
 13. The well screen apparatus according to claim 12, wherein the inward facing side of the wire wrap is longer and the outward facing side of the wire wrap is relatively shorter.
 14. The well screen apparatus according to claim 11, wherein the wire wrap has an inward facing side and an outward facing side, wherein the rib wire is connected to the wire wrap at the outward facing side of the wire wrap.
 15. The well screen apparatus according to claim 12, wherein the inward facing side of the wire wrap is longer and the outward facing side of the wire wrap is relatively shorter.
 16. The well screen apparatus, according to claim 11, wherein the wire wrap has a triangular shaped cross-sectional profile having an apex and a base, wherein the base of the wire wrap is in an inward facing direction and the apex of the wire wrap is in an outward facing direction.
 17. The well screen apparatus, according to claim 11, wherein the wire wrap has a trapezoidal shaped cross-sectional profile, the wire wrap having an inward facing side and an outward facing side, wherein the inward facing side is relatively longer than the outward facing.
 18. The well screen apparatus according to claim 11, further comprising a perforated pipe connected to the subsurface well screen apparatus.
 19. The well screen apparatus according to claim 18, further comprising another well screen disposed between the subsurface well screen and the perforated pipe.
 20. A method of providing a well screen in a subsurface environment for screening aggregate from and allowing flow of a volume of fluid and/or gas, comprising the steps of: mounting the well screen in the subsurface environment; and increasing the flow of the volume of fluid and/or gas in the subsurface environment whilst decreasing a flow velocity across the well screen for reducing erosion of the well screen. 